METHOD OF PROCESSING A GRAIN PRODUCT

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to methods for modifying a starch matrix within a gelatinized stable grain product to convert the grain product to relatively soft and formable grain pellets or pieces.

BACKGROUND OF THE INVENTION

[0002] A conventional manufacturer of pelletized cereal (grain) products regulates the desired texture, consistency, hardness and/or brittleness of the grain pellets by adjusting the moisture content of the pellets prior to converting the pellets into flakes or other ready-to-eat ("RTE") cereal products. Typically, such procedures include the steps of cooking, pelletizing, drying, flaking and toasting the grain in a sequential and substantially uninterrupted sequence of steps in a substantially continuous production process. Delays or separation between individual steps for operations in the sequential process increases the risk of undesirable physical and/or chemical changes in the properties of the grain product, which can result in inconsistent product characteristics that impact the desirability of the finished product to consumers.

[0003] In typical processes, the presence of moisture in the grain pellets renders them relatively soft and pliable, so that a subsequent forming operation, such as "bumping" (i.e., compressing between two rollers turning at substantially the same speed), flaking (e.g., with two rollers operating at different speeds), puffing, or other milling operation can be used to change the shape of the pellets, grits, or other pieces, in order to reach or closely approximate the desired finished shape of the grain product, such as for use in a ready-to-eat cereal product. If the grain pellets or pieces are not sufficiently soft and pliable, the flaking or other milling operation can shatter them, so that they cannot be formed to the desired finished shape.

[0004] Typically, a water activity value of approximately 0.75 or greater has been required to achieve satisfactory flaking, bumping, puffing, or other milling of the partially gelatinized grain pellets. "Water activity" is a unitless ratio defined as the vapor pressure of water contained within a substance (e.g., a grain product) at a given temperature, divided by the vapor pressure of pure water at the same temperature, and is generally considered to be a reliable measure of a product's ability to avoid mold or bacterial growth. Water activity also affects moisture migration between adjacent products having different moisture levels. For purposes of discussion, water activity may be thought of, in a simplified manner, as relating to the relative humidity of the air located in voids between particles within a grain product.

[0005] In traditional processes, once the grain pellets are flaked, bumped, or puffed to the general desired shape, they are typically toasted to achieve a ready-to-eat cereal product. In typical processes, the partially-gelatinized grain pellets, having a water activity value of about 0.75 or greater, will have a temperature of approximately 90 to 150 degrees Fahrenheit as they leave a drying step and enter a final forming stage of flaking, bumping, puffing, or the like. The grain product is typically moved directly to the final forming stage from the drying step, or from a cooling and tempering period to help equalize moisture within the grain product following drying, to limit or prevent the formation of mold on the grain product.

[0006] Processes that comprise multiple cycles of alternate heating and cooling steps are known eg from US2003/008049, US6139892, US2008/233258, US2011/274815 and US2012/244266.

SUMMARY OF THE INVENTION

[0007] According to the present invention there is provided a method of preparing a shelf-stable processed grain product as claimed in claim 1. Prior to the conditioning process, the grain particles have a low water activity value, typically about 0.65 or less, which inhibits or substantially prevents mold growth, but the starch molecules are also misaligned and at least partially gelatinized, which gives the grain particles a brittle or "glassy" characteristic that is not conducive to final forming processes. The conditioning process of the present invention modifies the internal structure and alignment of the starch matrix, thereby converting the texture or characteristic of the grain pellet, piece, or grit from a generally hard crystalline form to a relatively soft and pliable form, but without the need for adding moisture, which could make the grain product susceptible to mold growth.

[0008] According to one embodiment of the present invention, a method of preparing a shelf-stable processed grain product includes a series of heating and cooling/tempering steps performed on a processed grain product having a water activity value of about 0.65 or less. The method includes first, second and third heating steps, a first tempering step occurring between the first and second heating steps, and a second tempering step occurring between the second and third heating steps. The processed grain product initially has a relatively hard and brittle characteristic and, through the series of heating and tempering steps, achieves a relatively softer and more flexible characteristic. The first heating step takes the processed grain product to a first elevated temperature. The first tempering of the processed grain product takes the processed grain product to a first reduced temperature that is less than the first elevated temperature. The second heating of the processed grain product takes the processed grain product to a second elevated temperature that is greater than the first reduced temperature. The second tempering of the processed grain product whereby the processed grain product reaches a second reduced temperature that is less than the second elevated temperature. The third heating of the processed grain product takes the processed grain product to a third elevated temperature that is greater than the second reduced temperature. Once the processed grain product has completed the series of heating and tempering steps to achieve the desired softer and more flexible characteristic, it is ready for final forming such as flaking, bumping, puffing, or the like.

[0009] Thus, the present invention provides a method or system for modifying the structure of starch molecules in a processed grain product, such as for use in ready-to-eat cereals. The method utilizes a series of alternating heating and cooling/tempering steps to convert a relatively brittle but low water activity grain product, to a softened grain product that remains low in water activity value, but is softened and ready to be bumped, flaked, or puffed to achieve a finished or nearly finished cereal product. The ability to condition a brittle high density half product (grain pellet, grit, or naturally-shaped piece) with a low water activity value, into having a relatively soft or non-brittle material property or characteristic that retains a low water activity value, allows for indefinite-length storage and/or transport of the half product prior to final forming by flaking, bumping, or puffing the product. This adds flexibility to the manufacturing process and allows for more advantageous use of commodities and facilities used in grain processing, such as by reducing or eliminating the need to run a continuous step-by-step process.

[0010] These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 

FIG. 1 is a flow diagram depicting a method of processing a grain product in accordance with the present invention;

FIG. 2 is a diagram of a production area for use in conducting a heating and tempering portion of the method of FIG. 1;

FIG. 3 is a diagram of another embodiment of a production area for use in conducting a heating and tempering portion of the method of FIG. 1;

FIG. 4 is a side elevation of a grain conditioning and flaking apparatus that can be used in performing the method of the present invention:

FIG. 5 is an end elevation of the grain conditioning and flaking apparatus of FIG. 4; and

FIG. 6 is a top plan view of the grain conditioning and flaking apparatus of FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Referring now to the drawings and the illustrative embodiments depicted therein, a method of modifying the structure of starch molecules within a processed grain product allows for the creation of soft and formable grain pieces (typically pellets, grits, or naturally-shaped pieces) from dried grain pieces that previously had a hard and brittle consistency, but that were (and remain) relatively shelf-stable due to a low-water activity value. The soft and formable characteristic of the grain pieces facilitates final forming, such as by flaking, puffing, bumping, or the like. However, from the conclusion of an earlier drying step, the water activity value of the grain pieces is sufficiently low to inhibit mold growth, so that the later processing steps may be delayed far longer than has typically been possible in conventional grain processing methods. Therefore, the process of converting raw grains to finished cereal products may be separated or divided into separate processes, at separate locations, and with the option of storing the unfinished grain products for prolonged periods, even weeks or months, between the production of a dried and shelf-stable grain pellet or grit or naturally-shaped piece, and the final processing steps that result in a finished ready-to-eat cereal product, substantially without adversely affecting the quality or consistency of the final product.

[0013] In contrast to conventional grain processing, the present processing method 10 (FIG. 1) allows for grain pieces to be cooked and then dried to a relatively low water activity value (typically about 0.65 or less) at which they can be stored for prolonged periods, and then the grain pieces may be subsequently softened to achieve a soft or formable characteristic utilizing alternating heating and cooling/tempering of the grain pieces, and without need for the higher water activity values of conventional methods. In the illustrated embodiment of FIG. 1, raw grain products 12 (which may be any one or more of: rice, wheat, oats, barley, sorghum, corn, substantially any form of bran, or the like) are initially cooked 14 via substantially any known method, which results in a cooked grain product 16 that may be in the form of naturally-shaped particles or pieces. Cooked grain product 16 may be passed directly to a drying step 18 as naturally-shaped pieces or grits 19a, for example. Optionally, an intermediate pelletizing step 20 may be conducted in an agglomerator or the like, to convert selected grain components 19b (e.g., one or more types of bran, cracked wheat, etc.) of cooked grain product 16 into grain pellets 22, which are then passed along to drying step 18. The cooked grain product 16, whether in the form of naturally-shaped particles or grits 19a, or as grain pellets 22, is at least partially gelatinized, with starch molecules that are substantially misaligned within each grain pellet or particle, having a water activity value between about 0.93 and about 0.96, and a relatively soft texture or characteristic, before they enter drying step 18. The above-described steps of processing method 10, including cooking 14, drying 18 and pelletizing 20 may be performed using methods that are well known in the art.

[0014] Dried grain pieces 24 exit the drying step 18 with reduced moisture content and water activity compared to their moisture level and water activity when they entered the drying step 18. The water activity value of dried grain pieces 24 is at or below approximately 0.65, and typically is in the range of about 0.5 to 0.63. Preferably, the water activity value of dried grain pieces 24 is about 0.60 to about 0.63. In addition, the dried grain pieces 24 are no longer soft or deformable as when they entered drying step 18, and are now relatively hard or glassy upon exiting drying step 18. Optionally, a cooling step 26 is used to reduce the temperature of dried grain pieces 24 to approximately room temperature, following drying step 18. In this condition, cooled and dried grain pieces 29 have substantially non-aligned starch molecules and a water activity value of approximately 0.65 or less, so that cooled and dried grain pieces 29 may be stored for extended periods, for example six months or more, using conventional grain product storage and/or shipping methods and conditions, and substantially without compromising the product quality. However, in this state, cooled and dried grain pieces 29 are sufficiently hard and glassy so that further processing (flaking, bumping, puffing, etc.) generally cannot be performed with desirable results, because the brittle grain pieces would be shattered and pulverized into undesirably small particles.

[0015] In a more conventional process, the dried grain pieces have a sufficiently high water activity value when they exit a dryer so that they are sufficiently soft and formable to be passed directly into a final forming process such as flaking, bumping, puffing, etc. However, in the present processing method 10, the dried grain pieces are typically cooled and hardened to a dryer condition that is suitable for storage or shipping/transportation, but is less suitable to final forming processes for the reasons described above. The present method 10 applies a multi-step heating and cooling/tempering process 30 to cooled and dried grain pieces 31 (at least some of which may have been stored for an extended period), which process aligns the starch molecules within the grain pieces to achieve an amorphous plastic or rubbery or pliable consistency of the grain pieces, which conditions them for final forming, and which is accomplished substantially without the addition of moisture. This allows cooled and dried grain pieces 29 to be optionally stored and/or shipped or transported 28 for an extended period, in a shelf-stable condition, prior to the final forming.

[0016] In the illustrated embodiment of FIG. 1, multi-step heating and tempering process 30 is a five-step process in which heating and cooling/tempering steps are alternated in a manner that results in aligned starch molecules within the cooled and dried grain pieces 31 to achieve the desired amorphous plastic or rubbery or pliable consistency that is appropriate and ready for final forming, substantially without the further addition of moisture. Cooled and dried grain pieces 31, having a water activity value of about 0.65 or less, and a relatively hard and brittle characteristic or consistency, enter a first heating step 32 in which they achieve a first elevated temperature of about 170 degrees Fahrenheit. In first heating step 32, it is desirable to heat the grain pieces from room temperature at a rate sufficient to achieve the first elevated temperature of about 170 degrees Fahrenheit within a first heating period of about 5 to 15 seconds, such as by applying infrared radiation having a wavelength of about 0.7 microns. The grain pieces exit first heating step 32 and are cooled and tempered in a first cooling/tempering step 34 over a period of about 5 to 10 seconds, which relaxes the matrix of starch molecules (i.e., loosens or weakens their molecular bonds) within each grain piece, to thereby facilitate subsequent alignment of the starch molecules.

[0017] Following first tempering step 34, a second heating step 36 raises the temperature of the grain pieces to a second elevated temperature of about 210 degrees Fahrenheit. Preferably, second heating step 36 is performed over a period of about 10 to 20 seconds, optionally using infrared radiation having a wave length of about 0.5 microns, to reach the second elevated temperature from the first reduced temperature of first tempering step 34. The grain pieces are then directed from second heating step 36 to a second tempering step 38, to achieve a second reduced temperature, which is desirably reached in about 3 to 10 seconds, to align the starch molecules and the molecular bonds in the starch matrix. Following second tempering step 38, the grain pieces enter a third heating step 40, in which a third elevated temperature of about 210 degrees Fahrenheit is reached, to thereby to align the starch molecules with one another in the grain pieces. Preferably, the third elevated temperature of about of 210 degrees Fahrenheit is reached within a period of about 5 to 20 seconds of heating, using infrared radiation having a wavelength of about 0.7 microns.

[0018] Heated and tempered grain pieces 42 exit third heating step 40 with an amorphous plastic or rubbery or pliable consistency, and a water activity value that remains low (about 0.65 or less), and are ready for a final forming process 44, which may involve any one or more of flaking 46, puffing 48 and bumping 50, to achieve a formed grain product 52. The formed grain product 52 may then be directed to final processing steps such as toasting 54, and the application of one or more coatings 56, to obtain a finished ready-to-eat cereal product 58. It is generally desirable for heated and tempered grain pieces 42 to enter final forming process 44 sufficiently quickly so that the temperature of the grain pieces 42 is at least about 185 degrees Fahrenheit following the approximately 210 degrees Fahrenheit of third heating step 40, so that the grain pieces 42 do not become too brittle for the final forming process 44.

[0019] Optionally, heated and tempered grain pieces 42 may be directed into a cooling step 57 so that the temperature of the tempered grain pieces 42 drops below about 185 degrees Fahrenheit before the final forming process 44, and they can be stored or shipped/transported (e.g., via overland truck, train, ship, or other vehicle) as shelf-stable grain pieces 59. In that case, however, it will typically be necessary to conduct another multi-step heating and tempering process on the grain pieces 59, at higher temperatures than described above for process 30, to thereby re-condition the previously-tempered grain pieces 59 to be sufficiently soft and pliable for final forming process 44.

[0020] The multi-step heating and tempering process 30 of FIG. 1 may be performed using a system 60 (FIG. 2) having first, second and third infrared heaters 62a-c that are used to conduct first heating step 32, second heating step 36 and third heating step 40, respectively. In the preferred embodiment, the first infrared forming, but without making them susceptible to mold or bacterial growth. This permits delays for storage and/or shipping/transportation of the grain between various steps involved in processing, which increases the flexibility of the manufacturing process and allows for the more efficient utilization of equipment. For example, earlier steps of the grain processing method may be carried out, and the resultant partially processed products put into storage prior to carrying out further processing, even if equipment used in later processing steps is taken out of service for repair of maintenance. The partially processed grain products may be transported to a separate facility for final forming and processing, if necessary or desired.

[0021] Changes and modifications to the specifically-described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law, including the doctrine of equivalents.

[0022] In a further aspect the present invention comprises a multi-step grain conditioning apparatus comprising:

a conveyor configured to move grain pieces in a flow direction from an upstream portion to a downstream portion of said conveyor;

a first heater positioned along said conveyor near said upstream portion of said conveyor;

a second heater positioned along said conveyor between said upstream portion and said downstream portion of said conveyor, and spaced downstream from said first heater so as to provide a first cooling region along said conveyor between said first and second heaters; and

a third heater positioned along said conveyor near said downstream portion of said conveyor, and spaced downstream from said second heater so as to provide a second cooling/ cooling region along said conveyor between said second and third heaters; and

wherein said apparatus is operable to (i) heat the grain pieces to a first elevated temperature with said first heater, (ii) heat the grain pieces to a second elevated temperature with said second heater, and (iii) heat the grain pieces to a third elevated temperature with said third heater. Said conveyor may comprise a plurality of stepped surfaces and a vibratory motor operable to agitate the grain pieces and cause them to move along said conveyor in the flow direction, preferably further in combination with at least one chosen from: (i) a flaking mill, (ii) a bumping mill, and (iii) a puffing apparatus, which is operable to perform a final forming process on the grain pieces that exit said grain conditioning apparatus.

of dried grain pieces during heating and tempering process 30 improves the uniformity of all of the grain pieces that pass through system 60. Optionally, and as shown in FIG. 3, another system 60' has a belt conveyor 64' includes a series of descending steps that agitate or mix the dried grain pieces as they undergo the heating and tempering process 30, and that helps to ensure that substantially all sides of the grain pieces are exposed to radiant energy from the infrared heaters 62a-c.

[0023] It is envisioned that the multi-step heating and tempering process 30 and subsequent final forming process 44 may be performed on a single piece of machinery or equipment. For example, and with reference to FIGS. 4 and 5, a combination grain-conditioning and flaking mill 70 includes infrared heaters 62a-c and a stepped conveyor 64" at its upper end portion. Dried grain pieces are fed onto an upstream end portion of conveyor 64" via a feed chute 72, and they are moved along conveyor 64" (right to left as viewed in FIG. 4), on which they are heated by the infrared heaters 62a-c in sequence, with cooling/tempering areas located upstream and downstream from second heater 62b. Optionally, infrared heaters 62a-c may be pivotally mounted to an upper portion of a framework 74 via hinges 76, so that the heaters may be raised (shown in phantom in FIG. 5), such as for cleaning or servicing the conveyor 64".

[0024] In the illustrated embodiment of FIGS. 4-6, conveyor 64" has a stepped pan 78 that is vibrated by a vibratory motor 80 (FIGS. 4 and 5) supported on framework 74, which also supports stepped pan 78 via a plurality of vibration isolators 82. In the illustrated embodiment, another feed chute 81 directs the conditioned grain from a downstream end portion of stepped pan 78 to a pair of motor-driven rollers 84 that form the grain pieces into flakes. Rollers 84 may have a longitudinal length of about 40 inches and a diameter of about 26 inches, and may be turned at about 167rpm (about 1,137 linear feet per minute at the surface) by respective 75hp motors 86 (FIG. 5) turning at 1200rpm. When the rollers are turned at substantially the same speed as conditioned grain pieces pass between the rollers, this may be referred to as "bumping", while turning the rollers at different speeds from one another may be referred to as "flaking" the grain pieces. It will be appreciated that the rollers 84, motors 86, and substantially the entire grain-conditioning and flaking mill 70 may be scaled to substantially any desired size to meet particular throughput needs. Motors 86 are connected to the rollers 84 via respective belt drives 88 (FIG. 5). From rollers 84, the flakes drop through an outfeed chute 90 and into a hopper or another conveyor for final processing (e.g., toasting 54, coating 56, etc., such as shown in FIG. 1) of the flakes, prior to packaging. It will be appreciated that the rollers 84 of flaking mill 70 may be replaced with a puffing apparatus, a grinding mill, or other forming equipment to achieve a puffed or ground grain product, if desired, and without departing from the spirit and scope of the present invention.

[0025] Therefore, the present invention provides a method for converting shelf-stable grain particles from a hard crystalline structure to a pliable rubbery or soft texture, in order to prepare the grain particles for final forming, but without making them susceptible to mold or bacterial growth. This permits delays for storage and/or shipping/transportation of the grain between various steps involved in processing, which increases the flexibility of the manufacturing process and allows for the more efficient utilization of equipment. For example, earlier steps of the grain processing method may be carried out, and the resultant partially-processed products put into storage prior to carrying out further processing, even if equipment used in later processing steps is taken out of service for repair of maintenance. The partially processed grain products may be transported to a separate facility for final forming and processing, if necessary or desired.

[0026] Changes and modifications to the specifically-described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law, including the doctrine of equivalents.

Claims

1. A method (10) of preparing a shelf-stable processed grain product, said method comprising:

a first heating (32) of a processed grain product having an initial temperature and a water activity value of about 0.65 or less, the processed grain product further having an initial characteristic that is hard and brittle, whereby the processed grain product reaches a first elevated temperature that is higher than the initial temperature;

a first cooling (34) of the processed grain product whereby the processed grain product reaches a first reduced temperature that is less than the first elevated temperature;

a second heating (36) of the processed grain product whereby the processed grain product reaches a second elevated temperature that is greater than the first reduced temperature;

a second cooling (38) of the processed grain product whereby the processed grain product reaches a second reduced temperature that is less than the second elevated temperature; and

a third heating (40) of the processed grain product whereby the processed grain product reaches a third elevated temperature that is greater than the second reduced temperature, wherein each of said first heating, said second heating, and said third heating are performed substantially without addition of moisture to the processed grain product and wherein following said third heating (40) of the processed grain product, the processed grain product has a water activity value of about 0.65 or less and a subsequent characteristic that is softer and more pliable compared to the initial characteristic of the processed grain product prior to said first heating thereof.

2. The method of claim 1, wherein:

said first cooling (34) of the processed grain product is conducted over sufficient time and to a sufficient temperature to weaken molecular bonds within a starch matrix in the processed grain product;

said second cooling (38) of the processed grain product is conducted over sufficient time and to a sufficient temperature to align the molecular bonds within the starch matrix; and

said third heating (40) of the processed grain product is conducted over sufficient time and to a sufficient temperature to align the starch molecules with one another in the starch matrix in the processed grain product.

3. The method of claim 1, wherein:

said first heating (32) of the processed grain product is conducted for a period of about 5 to 15 seconds at a rate sufficient for the processed grain product to reach about 170 degrees Fahrenheit (77°C) as the first elevated temperature;

said first cooling of the processed grain product is conducted at a rate sufficient for the processed grain product to reach the first reduced temperature within a first cooling period of about 5 to 10 seconds;

said second heating of the processed grain product is conducted for a period of about 10 to 20 seconds at a rate sufficient for the processed grain product to reach about 210 degrees Fahrenheit (99°C) as the second elevated temperature;

said second cooling of the processed grain product is conducted at a rate sufficient for the processed grain product to reach the second reduced temperature within a second cooling period of about 3 to 10 seconds; and

said third heating of the processed grain product is conducted for a period of about 5 to 20 seconds at a rate sufficient for the processed grain product to reach about 210 degrees Fahrenheit (99°C) as the third elevated temperature.

4. The method of claim 1, further comprising final forming (44) of the processed grain product following said third heating (40), said final forming (44) comprising at least one chosen from (i) bumping (50), (ii) puffing (48), and (iii) flaking (46), of the processed grain product.

5. The method of claim 1, further comprising, prior to said first heating (32) of the processed grain product, at least one chosen from (i) storing (28) the processed grain product for a period of at least about 6 hours, and (ii) shipping (28) the processed grain product from a first location to a second location where said first, second and third heating, and said first and second cooling are conducted.

6. The method of claim 1, wherein:

said first heating (32) of the processed grain product causes the processed grain product to reach a temperature of about 170 degrees Fahrenheit (77°C);

said first cooling (34) of the processed grain product relaxing a starch matrix in the processed grain product;

said second heating (36) of the processed grain product causes the processed grain product to reach a temperature of about 210 degrees Fahrenheit (99°C);

said second cooling (38) of the processed grain product weakening the starch matrix and causing molecular bonds to be aligned within individual starch molecules of the starch matrix; and

said third heating (40) of the processed grain product substantially aligning the starch molecules in the starch matrix with one another in the processed grain product, and the processed grain product reaching a temperature of about 210 degrees Fahrenheit (99°C).

7. The method of claim 6, wherein at least one of:

said first heating (32) of the processed grain product is conducted over a period of about 5 to 15 seconds;

said first cooling (34) of the processed grain product is conducted over a period of about 5 to 10 seconds;

said second heating (36) of the processed grain product is conducted over a period of about 10 to 20 seconds;

said second cooling (38) of the processed grain product is conducted over a period of about 3 to 10 seconds; and

said third heating (40) of the processed grain product is conducted over a period of about 5 to 20 seconds.

8. The method of claim 6, wherein at least one of:

said first heating (32) of the processed grain product is performed with infrared radiation having a wavelength of about 0.7 microns;

said second heating (36) of the processed grain product is performed with infrared radiation having a wavelength of about 0.5 microns; and

said third heating (40) of the processed grain product is performed with infrared radiation having a wavelength of about 0.7 microns.

9. The method of claim 6, wherein:

said first heating (32) of the processed grain product is conducted over a period of about 5 to 15 seconds with infrared radiation having a wavelength of about 0.7 microns;

said first cooling (34) of the processed grain product is conducted over a period of about 5 to 10 seconds;

said second heating (36) of the processed grain product is conducted over a period of about 10 to 20 seconds with infrared radiation having a wavelength of about 0.5 microns;

said second cooling (38) of the processed grain product is conducted over a period of about 3 to 10 seconds; and

said third heating (40) of the processed grain product is conducted over a period of about 5 to 20 seconds with infrared radiation having a wavelength of about 0.7 microns.

10. The method of claim 6, further comprising dispensing the processed grain product as a layer of pellets, pieces, or grits (31,42) along a moving conveyor surface (64a, 64').

11. The method of claim 10, wherein at least one of said first, second and third heating steps (32,36,40) are conducted using infrared heating elements (62a,62b,62c) spaced about 4 to 8 inches (102 mm to 203 mm) from the layer of pellets, pieces, or grits (31,42) along the conveyor surface.

12. The method of claim 6, further comprising bumping (50) or flaking (46) the processed grain product following said third heating (40) of the processed grain product, to thereby produce a rolled or flaked grain product (52).

13. The method of claim 10, further comprising mixing or agitating the layer of pellets, pieces, or grits (31,42) along the conveyor surface (64a,64').

14. The method of claim 6, further comprising, prior to said first heating (32) of the processed grain product, at least one chosen from (i) storing (28) the processed grain product for a period of at least about 6 hours, and (ii) shipping (28) the processed grain product from a first location to a second location where said first, second and third heating, and said first and second cooling are conducted.

15. The method of claim 6, further comprising storing (28) the processed grain product for a period of at least about 1 month, prior to said first heating (32) of the processed grain product.

Ansprüche

1. Verfahren (10) zum Zubereiten eines haltbaren industriell verarbeiteten Getreideprodukts, wobei das Verfahren Folgendes umfasst:

ein erstes Erwärmen (32) eines industriell verarbeiteten Getreideprodukts mit einer Ausgangstemperatur und einem Wasseraktivitätswert von ungefähr 0,65 oder weniger, wobei das industriell verarbeitete Getreideprodukt weiter eine Ausgangscharakteristik aufweist, die hart und spröd ist, wodurch das industriell verarbeitete Getreideprodukt eine erste erhöhte Temperatur erreicht, die höher als die Ausgangstemperatur ist;

ein erstes Abkühlen (34) des industriell verarbeiteten Getreideprodukts, wodurch das industriell verarbeitete Getreideprodukt eine erste gesenkte Temperatur erreicht, die tiefer als die erste erhöhte Temperatur ist;

ein zweites Erwärmen (36) des industriell verarbeiteten Getreideprodukts, wodurch das industriell verarbeitete Getreideprodukt eine zweite erhöhte Temperatur erreicht, die höher als die erste gesenkte Temperatur ist;

ein zweites Abkühlen (38) des industriell verarbeiteten Getreideprodukts, wodurch das industriell verarbeitete Getreideprodukt eine zweite gesenkte Temperatur erreicht, die tiefer als die zweite erhöhte Temperatur ist; und

ein drittes Erwärmen (40) des verarbeiteten Getreideprodukts, wodurch das industriell verarbeitete Getreideprodukt eine dritte erhöhte Temperatur erreicht, die höher als die zweite gesenkte Temperatur ist, wobei das erste Erwärmen, das zweite Erwärmen und das dritte Erwärmen jeweils im Wesentlichen ohne Zugabe von Feuchtigkeit zu dem industriell verarbeiteten Getreideprodukt durchgeführt werden, und wobei nach dem dritten Erwärmen (40) des industriell verarbeiteten Getreideprodukts das industriell verarbeitete Getreideprodukt einen Wasseraktivitätswert von ungefähr 0,65 oder weniger und eine anschließende Charakteristik, die, verglichen mit der Ausgangscharakteristik des industriell verarbeiteten Getreideprodukts vor dem ersten Erwärmen desselben, weicher und nachgiebiger ist, aufweist.

2. Verfahren nach Anspruch 1, wobei:

das erste Abkühlen (34) des industriell verarbeiteten Getreideprodukts über eine ausreichende Zeit hinweg und auf eine ausreichende Temperatur ausgeführt wird, um Molekularbindungen innerhalb einer Stärkematrix in dem industriell verarbeiteten Getreideprodukt zu schwächen;

das zweite Abkühlen (38) des industriell verarbeiteten Getreideprodukts über eine ausreichende Zeit hinweg und auf eine ausreichende Temperatur ausgeführt wird, um die Molekularbindungen innerhalb der Stärkematrix auszurichten; und

das dritte Erwärmen (40) des industriell verarbeiteten Getreideprodukts über eine ausreichende Zeit hinweg und auf eine ausreichende Temperatur ausgeführt wird, um die Stärkemoleküle in der Stärkematrix des industriell verarbeiteten Getreideprodukts aufeinander auszurichten.

3. Verfahren nach Anspruch 1, wobei:

das erste Erwärmen (32) des industriell verarbeiteten Getreideprodukts für einen Zeitraum von ungefähr 5 bis 15 Sekunden mit einer Geschwindigkeit ausgeführt wird, die ausreicht, dass das industriell verarbeitete Getreideprodukt ungefähr 170 Grad Fahrenheit (77 °C) als die erste erhöhte Temperatur erreicht;

das erste Abkühlen des industriell verarbeiteten Getreideprodukts mit einer Geschwindigkeit ausgeführt wird, die ausreicht, dass das industriell verarbeitete Getreideprodukt die erste gesenkte Temperatur innerhalb eines ersten Abkühlzeitraums von ungefähr 5 bis 10 Sekunden erreicht;

das zweite Erwärmen des industriell verarbeiteten Getreideprodukts für einen Zeitraum von ungefähr 10 bis 20 Sekunden mit einer Geschwindigkeit ausgeführt wird, die ausreicht, dass das industriell verarbeitete Getreideprodukt ungefähr 210 Grad Fahrenheit (99 °C) als die zweite erhöhte Temperatur erreicht;

das zweite Abkühlen des industriell verarbeiteten Getreideprodukts mit einer Geschwindigkeit ausgeführt wird, die ausreicht, dass das industriell verarbeitete Getreideprodukt die zweite gesenkte Temperatur innerhalb eines zweiten Abkühlzeitraums von ungefähr 3 bis 10 Sekunden erreicht; und

das dritte Erwärmen des industriell verarbeiteten Getreideprodukts für einen Zeitraum von ungefähr 5 bis 20 Sekunden mit einer Geschwindigkeit ausgeführt wird, die ausreicht, dass das industriell verarbeitete Getreideprodukt ungefähr 210 Grad Fahrenheit (99 °C) als die dritte erhöhte Temperatur erreicht.

4. Verfahren nach Anspruch 1, weiter umfassend das endgültige Formen (44) des industriell verarbeiteten Getreideprodukts nach dem dritten Erwärmen (40), wobei das endgültige Formen (44) mindestens eines umfasst, das aus (i) Bumping (50), (ii) Puffen (48) und (iii) Flocken (46) des industriell verarbeiteten Getreideprodukts ausgewählt wird.

5. Verfahren nach Anspruch 1, weiter umfassend, vor dem ersten Erwärmen (32) des industriell verarbeiteten Getreideprodukts, mindestens eines, das ausgewählt wird aus: (i) Lagern (28) des industriell verarbeiteten Getreideprodukts für einen Zeitraum von mindestens ungefähr 6 Stunden und (ii) Transportieren (28) des industriell verarbeiteten Getreideprodukts von einem ersten Ort zu einem zweiten Ort, an dem das erste, das zweite und das dritte Erwärmen und das erste und das zweite Abkühlen ausgeführt werden.

6. Verfahren nach Anspruch 1, wobei:

das erste Erwärmen (32) des industriell verarbeiteten Getreideprodukts bewirkt, dass das industriell verarbeitete Getreideprodukt eine Temperatur von ungefähr 170 Grad Fahrenheit (77 °C) erreicht;

das erste Abkühlen (34) des industriell verarbeiteten Getreideprodukts eine Stärkematrix in dem industriell verarbeiteten Getreideprodukt entspannt;

das zweite Erwärmen (36) des industriell verarbeiteten Getreideprodukts bewirkt, dass das industriell verarbeitete Getreideprodukt eine Temperatur von ungefähr 210 Grad Fahrenheit (99 °C) erreicht;

das zweite Abkühlen (38) des industriell verarbeiteten Getreideprodukts die Stärkematrix schwächt und bewirkt, dass Molekularbindungen innerhalb einzelner Stärkemoleküle der Stärkematrix ausgerichtet werden; und

das dritte Erwärmen (40) des industriell verarbeiteten Getreideprodukts im Wesentlichen die Stärkemoleküle in der Stärkematrix in dem industriell verarbeiteten Getreideprodukt aufeinander ausrichtet und das industriell verarbeitete Getreideprodukt eine Temperatur von ungefähr 210 Grad Fahrenheit (99 °C) erreicht.

7. Verfahren nach Anspruch 6, wobei mindestens eines der Folgenden gilt:

das erste Erwärmen (32) des industriell verarbeiteten Getreideprodukts wird über einen Zeitraum von ungefähr 5 bis 15 Sekunden hinweg ausgeführt;

das erste Abkühlen (34) des industriell verarbeiteten Getreideprodukts wird über einen Zeitraum von ungefähr 5 bis 10 Sekunden hinweg ausgeführt;

das zweite Erwärmen (36) des industriell verarbeiteten Getreideprodukts wird über einen Zeitraum von ungefähr 10 bis 20 Sekunden hinweg ausgeführt;

das zweite Abkühlen (38) des industriell verarbeiteten Getreideprodukts wird über einen Zeitraum von ungefähr 3 bis 10 Sekunden hinweg ausgeführt; und

das dritte Erwärmen (40) des industriell verarbeiteten Getreideprodukts wird über einen Zeitraum von ungefähr 5 bis 20 Sekunden hinweg ausgeführt.

8. Verfahren nach Anspruch 6, wobei mindestens eines der Folgenden gilt:

das erste Erwärmen (32) des industriell verarbeiteten Getreideprodukts wird mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,7 Mikrometern durchgeführt;

das zweite Erwärmen (36) des industriell verarbeiteten Getreideprodukts wird mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,5 Mikrometern durchgeführt; und

das dritte Erwärmen (40) des industriell verarbeiteten Getreideprodukts wird mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,7 Mikrometern durchgeführt.

9. Verfahren nach Anspruch 6, wobei:

das erste Erwärmen (32) des industriell verarbeiteten Getreideprodukts über einen Zeitraum von ungefähr 5 bis 15 Sekunden hinweg mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,7 Mikrometern ausgeführt wird;

das erste Abkühlen (34) des industriell verarbeiteten Getreideprodukts über einen Zeitraum von ungefähr 5 bis 10 Sekunden hinweg ausgeführt wird;

das zweite Erwärmen (36) des industriell verarbeiteten Getreideprodukts über einen Zeitraum von ungefähr 10 bis 20 Sekunden hinweg mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,5 Mikrometern ausgeführt wird;

das zweite Abkühlen (38) des industriell verarbeiteten Getreideprodukts über einen Zeitraum von ungefähr 3 bis 10 Sekunden hinweg ausgeführt wird; und

das dritte Erwärmen (40) des industriell verarbeiteten Getreideprodukts über einen Zeitraum von ungefähr 5 bis 20 Sekunden hinweg mit Infrarotstrahlung mit einer Wellenlänge von ungefähr 0,7 Mikrometern ausgeführt wird.

10. Verfahren nach Anspruch 6, weiter umfassend das Ausgeben des industriell verarbeiteten Getreideprodukts als eine Schicht aus Pellets, Stücken oder Schrot (31, 42) entlang einer sich bewegenden Fördereroberfläche (64a, 64').

11. Verfahren nach Anspruch 10, wobei mindestens einer aus dem ersten, dem zweiten und dem dritten Erwärmungsschritt (32, 36, 40) unter Verwendung von Infrarotheizelementen (62a, 62b, 62c) ausgeführt werden, die ungefähr 4 bis 8 Zoll (102 mm bis 203 mm) von der Schicht aus Pellets, Stücken oder Schrot (31, 42) entlang der Fördereroberfläche beabstandet sind.

12. Verfahren nach Anspruch 6, weiter umfassend das Bumping (50) oder Flocken (46) des industriell verarbeiteten Getreideprodukts nach dem dritten Erwärmen (40) des industriell verarbeiteten Getreideprodukts, um dadurch ein gewalztes oder geflocktes Getreideprodukt (52) zu erzeugen.

13. Verfahren nach Anspruch 10, weiter umfassend das Mischen oder Schütteln der Schicht aus Pellets, Stücken oder Schrot (31, 42) entlang der Fördereroberfläche (64a, 64').

14. Verfahren nach Anspruch 6, weiter umfassend, vor dem ersten Erwärmen (32) des industriell verarbeiteten Getreideprodukts, mindestens eines, das ausgewählt wird aus: (i) Lagern (28) des industriell verarbeiteten Getreideprodukts für einen Zeitraum von mindestens ungefähr 6 Stunden und (ii) Transportieren (28) des industriell verarbeiteten Getreideprodukts von einem ersten Ort zu einem zweiten Ort, an dem das erste, das zweite und das dritte Erwärmen und das erste und das zweite Abkühlen ausgeführt werden.

15. Verfahren nach Anspruch 6, weiter umfassend das Lagern (28) des industriell verarbeiteten Getreideprodukts für einen Zeitraum von mindestens ungefähr 1 Monat vor dem ersten Erwärmen (32) des industriell verarbeiteten Getreideprodukts.

Revendications

1. Procédé (10) servant à préparer un produit céréalier transformé de longue conservation ledit procédé comportant :

une première étape consistant à chauffer (32) un produit céréalier transformé ayant une température initiale et une valeur d'activité de l'eau d'environ 0,65 ou moins, le produit céréalier transformé ayant par ailleurs une caractéristique initiale qui est dure et cassante, ce par quoi le produit céréalier transformé atteint une première température élevée qui est supérieure à la température initiale ;

une première étape consistant à refroidir (34) le produit céréalier transformé ce par quoi le produit céréalier transformé atteint une première température réduite qui est inférieure à la première température élevée ;

une deuxième étape consistant à chauffer (36) le produit céréalier transformé ce par quoi le produit céréalier transformé atteint une deuxième température élevée qui est supérieure à la première température réduite ;

une deuxième étape consistant à refroidir (38) le produit céréalier transformé ce par quoi le produit céréalier transformé atteint une deuxième température réduite qui est inférieure à la deuxième température élevée ; et

une troisième étape consistant à chauffer (40) le produit céréalier transformé ce par quoi le produit céréalier transformé atteint une troisième température élevée qui est supérieure à la deuxième température réduite, dans lequel chacune parmi ladite première étape consistant à chauffer, ladite deuxième étape consistant à chauffer, et ladite troisième étape consistant à chauffer sont exécutées sensiblement sans ajout d'humidité au produit céréalier transformé et dans lequel à la suite de ladite troisième étape consistant à chauffer (40) le produit céréalier transformé, le produit céréalier transformé a une valeur d'activité de l'eau d'environ 0,65 ou moins et une caractéristique ultérieure qui est plus souple et plus flexible par rapport à la caractéristique initiale du produit céréalier transformé avant ladite première étape consistant à chauffer celui-ci.

2. Procédé selon la revendication 1, dans lequel :

ladite première étape consistant à refroidir (34) le produit céréalier transformé est effectuée sur une durée suffisante et à une température suffisante pour affaiblir les liaisons moléculaires dans une matrice d'amidon dans le produit céréalier transformé ;

ladite deuxième étape consistant à refroidir (38) le produit céréalier transformé est effectuée sur une durée suffisante et à une température suffisante pour aligner les liaisons moléculaires dans la matrice d'amidon ; et

ladite troisième étape consistant à chauffer (40) le produit céréalier transformé est effectuée sur une durée suffisante et à une température suffisante pour aligner les molécules d'amidon les unes par rapport aux autres dans la matrice d'amidon dans le produit céréalier transformé.

3. Procédé selon la revendication 1, dans lequel :

ladite première étape consistant à chauffer (32) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 15 secondes à une vitesse suffisante pour que le produit céréalier transformé atteigne environ 170 degrés Fahrenheit (77°C) comme première température élevée ;

ladite première étape consistant à refroidir le produit céréalier transformé est effectuée à une vitesse suffisante pour que le produit céréalier transformé atteigne la première température réduite dans les limites d'une première période de refroidissement allant d'environ 5 à 10 secondes ;

ladite deuxième étape consistant à chauffer le produit céréalier transformé est effectuée au cours d'une période allant d'environ 10 à 20 secondes à une vitesse suffisante pour que le produit céréalier transformé atteigne environ 210 degrés Fahrenheit (99°C) comme deuxième température élevée ;

ladite deuxième étape consistant à refroidir le produit céréalier transformé est effectuée à une vitesse suffisante pour que le produit céréalier transformé atteigne la deuxième température réduite dans les limites d'une deuxième période de refroidissement allant d'environ 3 à 10 secondes ; et

ladite troisième étape consistant à chauffer le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 20 secondes à une vitesse suffisante pour que le produit céréalier transformé atteigne environ 210 degrés Fahrenheit (99°C) comme troisième température élevée.

4. Procédé selon la revendication 1, comportant par ailleurs l'étape consistant à effectuer une formation finale (44) du produit céréalier transformé à la suite de ladite troisième étape consistant à chauffer (40), ladite étape consistant à effectuer la formation finale (44) comportant au moins l'une choisie parmi les étapes consistant à (i) bosseler (50), (ii) souffler (48), et (iii) émietter (46), le produit céréalier transformé.

5. Procédé selon la revendication 1, comportant par ailleurs, avant ladite première étape consistant à chauffer (32) le produit céréalier transformé, au moins l'une choisie parmi les étapes consistant à (i) stocker (28) le produit céréalier transformé au cours d'une période d'au moins environ 6 heures, et (ii) expédier (28) le produit céréalier transformé depuis un premier emplacement jusqu'à un deuxième emplacement où lesdites première, deuxième et troisième étapes consistant à chauffer, et lesdites première et deuxième étapes consistant à refroidir sont effectuées.

6. Procédé selon la revendication 1, dans lequel :

ladite première étape consistant à chauffer (32) le produit céréalier transformé amène le produit céréalier transformé à atteindre une température d'environ 170 degrés Fahrenheit (77°C) ;

ladite première étape consistant à refroidir (34) le produit céréalier transformé permet une relaxation d'une matrice d'amidon dans le produit céréalier transformé ;

ladite deuxième étape consistant à chauffer (36) le produit céréalier transformé amène le produit céréalier transformé à atteindre une température d'environ 210 degrés Fahrenheit (99°C) ;

ladite deuxième étape consistant à refroidir (38) le produit céréalier transformé permet un affaiblissement de la matrice d'amidon et amène des liaisons moléculaires à s'aligner dans des molécules d'amidon individuelles de la matrice d'amidon ; et

ladite troisième étape consistant à chauffer (40) le produit céréalier transformé permet de sensiblement aligner les molécules d'amidon dans la matrice d'amidon les unes par rapport aux autres dans le produit céréalier transformé, et permet au produit céréalier transformé d'atteindre une température d'environ 210 degrés Fahrenheit (99°C).

7. Procédé selon la revendication 6, dans lequel au moins l'un parmi :

ladite première étape consistant à chauffer (32) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 15 secondes ;

ladite première étape consistant à refroidir (34) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 10 secondes ;

ladite deuxième étape consistant à chauffer (36) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 10 à 20 secondes ;

ladite deuxième étape consistant à refroidir (38) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 3 à 10 secondes ; et

ladite troisième étape consistant à chauffer (40) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 20 secondes.

8. Procédé selon la revendication 6, dans lequel au moins l'une parmi :

ladite première étape consistant à chauffer (32) le produit céréalier transformé est exécutée au moyen d'un rayonnement infrarouge ayant une longueur d'onde d'environ 0,7 microns ;

ladite deuxième étape consistant à chauffer (36) le produit céréalier transformé est exécutée au moyen d'un rayonnement infrarouge ayant une longueur d'onde d'environ 0,5 microns ; et

ladite troisième étape consistant à chauffer (40) le produit céréalier transformé est exécuté au moyen d'un rayonnement infrarouge d'une longueur d'onde d'environ 0,7 microns.

9. Procédé selon la revendication 6, dans lequel :

ladite première étape consistant à chauffer (32) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 15 secondes au moyen d'un rayonnement infrarouge d'une longueur d'onde d'environ 0,7 microns ;

ladite première étape consistant à refroidir (34) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 10 secondes ;

ladite deuxième étape consistant à chauffer (36) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 10 à 20 secondes au moyen d'un rayonnement infrarouge d'une longueur d'onde d'environ 0,5 microns ;

ladite deuxième étape consistant à refroidir (38) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 3 à 10 secondes ; et

ladite troisième étape consistant à chauffer (40) le produit céréalier transformé est effectuée au cours d'une période allant d'environ 5 à 20 secondes au moyen d'un rayonnement infrarouge d'une longueur d'onde d'environ 0,7 microns.

10. Procédé selon la revendication 6, comportant par ailleurs l'étape consistant à distribuer le produit céréalier transformé sous la forme d'une couche de granulés, de morceaux, ou de gruaux (31, 42) le long d'une surface de transporteur mobile (64a, 64').

11. Procédé selon la revendication 10, dans lequel au moins l'une desdites première, deuxième et troisième étapes consistant à chauffer (32, 36, 40) sont effectuées au moyen d'éléments de chauffage par infrarouge (62a, 62b, 62c) espacés d'environ 4 à 8 pouces (102 mm à 203 mm) par rapport à la couche de granulés, de morceaux, ou de gruaux (31, 42) le long d'une surface de transporteur.

12. Procédé selon la revendication 6, comportant par ailleurs l'étape consistant à bosseler (50) ou à émietter (46) le produit céréalier transformé à la suite de ladite troisième étape consistant à chauffer (40) le produit céréalier transformé, pour ainsi produire un produit céréalier laminé ou émietté (52).

13. Procédé selon la revendication 10, comportant par ailleurs l'étape consistant à mélanger ou à agiter la couche de granulés, de morceaux, ou de gruaux (31, 42) le long de la surface de transporteur (64a, 64').

14. Procédé selon la revendication 6, comportant par ailleurs, avant ladite première étape consistant à chauffer (32) le produit céréalier transformé, au moins l'une choisie parmi les étapes consistant à (i) stocker (28) le produit céréalier transformé au cours d'une période d'au moins environ 6 heures, et (ii) expédier (28) le produit céréalier transformé depuis un premier emplacement jusqu'à un deuxième emplacement où lesdits première, deuxième et troisième étapes consistant à chauffer, et lesdites première et deuxième étapes consistant à refroidir sont effectuées.

15. Procédé selon la revendication 6, comportant par ailleurs l'étape consistant à stocker (28) le produit céréalier transformé au cours d'une période d'au moins environ 1 mois, avant ladite première étape consistant à chauffer (32) le produit céréalier transformé.

Drawing